Spikeless tie plate fasteners, pre-plated railroad ties and related assemblies and methods

ABSTRACT

Railroad tie plates secured collectively by spikeless fasteners to a tie with railroad spikes securing the rails to the ties and related methodology are disclosed wherein two-part fasteners are used in respect to sets of aligned tie and tie plate apertures such that the two fastener parts are joined together against inadvertent separation within each tie aperture at a connection or union site, which includes but is not limited to force fit unions and threaded unions, and spikes are driven into the ties through other tie plate apertures.

CONTINUITY

This application is a continuation-in-part of my co-pending U.S. patent application Ser. No. 11/089,164, filed Mar. 24, 2005.

FIELD OF INVENTION

The present invention relates generally to tie-supported railroad tracks and more particularly to spikeless tie plate fasteners, pre-plated railroad ties having at least one spikeless tie plate fastener and at least one spike fastener through each tie plate, related assemblies and methods.

BACKGROUND

In regard to railroad ties formed of wooden, plastic and composite materials, some of which may comprise one piece or multiple layers, traditionally only spikes are driven through apertures in two-spaced tie plates, each placed on top of each tie, into non-apertured tie locations. The extent to which the spikes, once driven, and the tie plates through which the spikes pass are held in place depends on the compression forces of the tie material against each spike. If the spikes loosen, the associated tie plate will also loosen, creating a potential for damage and a danger for trains traveling over the track. When spikes loosen, the layers of multi-layered ties, when used, may separate and shift. While the driven-spike-only approach typically works well with soft wood and other soft materials, it often does not with hard woods and other hard materials. While hard wood ties last longer than soft wood ties, hard wood ties are too often split by the spikes as the spikes are driven. Thus, the split hard wood tie does not compressively hold the spikes in the fully driven position and the tie plates become loose creating the potential for damage and danger as mentioned above.

Use of nut and bolt fasteners in lieu of and/or together with spikes for hard wood ties has heretofore been rejected in the railroad industry because of the cost of pre-drilling the ties and the nut and bolt fasteners, and difficulty in stacking such pre-plated ties in inventory and on transportation vehicles. Tightening of such bolts into associated nuts, to retain an associated tie plate tightly on the tie, has been problematic because the nut not only extends below the bottom of the tie, but often rotates as the bolt is rotated.

Screw spikes, which tend to cause the tie to split, have also been proposed for holding tie plates correctly on top of railroad ties, but the screw spikes tend to fracture, under the forces of train vibration over time, at the reduced diameter site located between the shank and the top of the threads.

Use of multiple layer ties has fallen into disfavor, largely because of layer separation and shifting.

Based on the prior art described above, it would be a major break through to provide effective spikeless tie plate fasteners, reliable pre-plated railroad ties having at least one spikeless tie plate fastener and at least one spike fastener in each tie plate, and related assemblies and methods.

BRIEF SUMMARY AND OBJECTS OF THE INVENTION

In brief summary, the present invention overcomes or substantially alleviates problems of the past related to securing tie plates to railroad ties, especially, but not limited to, dense ties comprised, for example, of hard woods and other dense materials. More specifically, the present invention is directed to novel spikeless tie plate fasteners, pre-plated railroad ties having at least one spikeless tie plate fastener and at least one spike fastener in each tie plate, railroad tracks comprising such and related assemblies and methodology.

Railroad ties, including those formed of hard wood, synthetic resin and composite material, formed as one piece or in layers, are apertured top to bottom with an at least one aperture matching the location of an aperture in each of two tie plates. With one tie aperture aligned with one tie plate aperture in both tie plates, the two-parts of the fastener are oppositely inserted into each pair of aligned apertures. The two fastener parts in both aligned pairs of apertures are joined together against inadvertent separation within the associated tie aperture at a connection or union site, between the two fastener parts, which includes but is not limited to force-fit unions and threaded unions. When spikes are used to secure the rails, at least one spike is driven through at least one other aperture in each tie plate into undrilled tie material. Thus, each such tie plate is secured by one or more of the above-mentioned nut and bolt fasteners and by one or more driven spikes.

Typically, each two-part fastener comprises a first or top shaft fastener member inserted through aligned tie plate and tie apertures so that a proximal head thereof is contiguous with the top surface of the associate tie plate. A distal end portion of the first fastener member is disposed within the associated tie aperture and is not connected to the tie. The distal end portion, in the assembled state, is disposed above the bottom surface of the tie in the associated tie aperture. The other, lower or bottom fastener member is inserted from the bottom of the tie into the associate tie aperture, in non-rotatable relation. The other fastener member is preferably entirely disposed within the associate tie aperture (to better allow stacking of pre-plated railroad ties in inventory and on transportation vehicles) and may be covered by a layer or seal for the purpose of protecting the other fastener member from corrosion infiltrating from the ballast. The two-part fastener prevents or alleviates layer separation and shifting when used with multi-layered ties.

With the foregoing in mind, it is a primary object of the present invention to overcome or substantially alleviate problems of the past related to securing tie plates to railroad ties.

Another paramount object is the provision of a novel system, unique assemblies and distinct methodology for building railroads, pre-plating railroad ties comprising at least one spikeless fastener and at least one driven spike, the spikeless fastener comprising two-parts for use in pre-formed apertures of railroad ties to assist in securing tie plates in position, which features are especially effective with ties formed of hard dense material, such as hard woods, high molecular weight plastics and dense composites.

Another important object is the provision of novel spikeless tie plate fasteners, pre-plated railroad ties using both spikeless fasteners and spikes to secure tie plates to the ties, railroad tracks comprised of such, and related assemblies and methodology.

Another significant object is to provide novel combinations comprised of a multi-layered railroad tie, tie plates and two-part spikeless fasteners, which prevent or alleviate layer separation and layer shifting.

These and other objects and features of the present invention will be apparent from the following detailed description taken with reference to the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an exploded perspective of a two-part fastener in accordance with principles of the present invention.

FIG. 2 is a perspective of a second lower fastener member, which may be substituted for the lower fastener member FIG. 1;

FIG. 3 is a fragmentary perspective of a railroad tie, which may be monolithic or comprised of layers, having a tie plate mounted at the top surface thereof, using the two-part fasteners illustrated in FIG. 1.

FIG. 4 is an enlarged fragmentary cross-section taken along lines 4-4 of FIG. 3;

FIG. 5 is a bottom plan view taken along line 5-5 of FIG. 4;

FIG. 6 is a bottom plan view taken along line 6-6 of FIG. 7;

FIG. 7 is an enlarged fragmentary cross-section, similar to FIG. 4, illustrating the railroad tie of plastic or composite material as opposed to hard wood;

FIG. 8 is a fragmentary elevation shown partly in cross-section depicting a two-part fastener which may be used in lieu of the two-part fastener of FIG. 1 and which is adapted to create a force fit union within a tie aperture between the two fastener parts;

FIG. 9 is a fragmentary elevation, with a part broken away for clarity, illustrating an additional two-part fastener in accordance with principles of the present invention;

FIG. 10 is a diagrammatic representation of the manner in which railroad ties may be pre-plated and stored or transported, in accordance with principles of the present invention;

FIG. 11 is a fragmentary perspective of a tie plate, having six apertures, placed at a proper site on the top of a railroad tie, which may be monolithic or comprised of layers; and

FIG. 12 is a fragmentary perspective of the tie plate of FIG. 11 secured to the tie by two recessed, two-part fasteners, with a rail shown secured to the tie plate by four railroad spikes.

DETAILED DESCRIPTION OF THE ILLUSTRATED EMBODIMENTS

Reference is now made to the drawings wherein like numerals are used to designate like parts throughout. As mentioned above, when hard wood ties are used to build or renovate a railroad track, the traditional method of utilizing railroad spikes is often counterproductive because the spikes tend to split the hard wood so that the embedded end of the spikes are not held tightly in position and, therefore, loosen responsive to railroad vibrations as trains move along the track. This can and does create certain risks of damage and danger and increases the amount of maintenance attention required. The same difficulty tends to exist when other dense materials are used, such as high molecular weight synthetic resinous materials and dense composite materials. While the present invention is directed toward railroad ties made of dense material, the present invention works well with softer tie materials, such as soft woods.

Central to the present invention is to utilize preformed apertures in railroad ties into which novel two-part fasteners are placed. One such two-part fastener is illustrated in FIG. 1, to which reference is now made.

The two-part fastener of FIG. 1 is generally designated 20 and comprises first and second fastener members, generally designated 22 and 24, respectively. The two-part fastener 20 is adapted to be used in lieu of a railroad spike to resolve or alleviate the tie splitting problem mentioned above. The first or top fastener member 22 comprises a male or shaft fastener member comprising distal threads 26, a smooth shank 28 above the threads 26 and a proximal head, generally designated 30.

The head 30 comprises a diametrally enlarged flange 32, the diameter of which is substantially greater than the diameter of the shaft comprising shank 28 and threads 26 and substantially greater in diameter than the apertures preformed in the railroad ties, as explained hereinafter in greater detail. The head 30 also comprises an upwardly extending square-shaped four-sided projection by which the fastener member 22 is rotated using a conventional wrench or the like. The head 30 is adapted to be exposed above a tie plate after the plate is placed on the top of a railroad tie, so that the enlarged annulus or flange 32 rests contiguously and forcibly upon the top surface of the associated tie plate, as explained herein in greater detail.

While any one of several materials may be utilized to form fastener member 22, currently for cost and reliability purposes, a high grade steel is preferred.

With continued reference to FIG. 1, the second fastener member 24 comprises a boss 36 comprising a hollow interior defined by internal threads 38. The boss 36 is illustrated as being crimped or indented at site 40, which reduces the diameter of the internal threads 38 in a localized region. The boss 36 is formed as one piece or integrated with an anti-rotate eccentric base 42, illustrated as being planar or plate-like. When the second fastener member 24 is placed in a stepped aperture from the bottom of a railroad tie, as illustrated in FIG. 4, the eccentric relationship between the center line of the boss 36 and the center line of the base 42, when positioned as illustrated in FIG. 4, prevents the fastener member 24 from rotating as the fastener member 22 is turned causing matching or mating threads 26 and 38 to become threadedly connected, with the crimp 40 preventing inadvertent reverse rotation of threads 26 in respect to threads 38. Thus, the insertion and, if necessary, removal of fastener 20 can be accomplished from above the tie.

Reference is now made to FIG. 2, which illustrates a second form of a lower fastener member, generally designated 24′, comprising the previously described boss 36, equipped with two opposed crimps or indentations 40 to prevent inadvertent reverse rotation or the top fastener member, as explained above. The boss 36 of FIG. 2 is formed as one piece or as integrated with a rectangular or square base 42′, which is flat or planar in its configuration and, when placed in a rectangular recess at the lower part of a vertical aperture in a railroad tie, as shown in FIG. 7, becomes an anti-rotate component preventing boss 24′ from turning as fastener 22 is threaded into threads 38 of the lower fastener member 24′.

When the two-part fastener of FIG. 1 or a two-part fastener comprising fastener member 22 FIG. 1 and fastener member 24′ of FIG. 2 are properly assembled with a tie plate and a pre-apertured railroad tie, the configuration illustrated in FIG. 3 results. In FIG. 3, the railroad, either monolithic or layered, tie is generally designated 44 and comprises a top surface 45 and a bottom surface 47. The dotted line 49 denotes the interface between two or more layers 51 when a multi-layer tie is used. The layers may simply be aligned and contiguous at interface 49, or part or all of the interface 49 may receive a suitable bonding agent to adhere the layers together. The tie plate, which is conventional, is generally designated 46. Tie plate 46 comprises a central flat region 48 upon which a railroad rail is placed and is conventionally secured, by structure not shown. Two tie plates are used at the top of each railroad tie, so located to accommodate two railroad ties having the proper gauge for the railroad track in question.

Reference is now made to FIG. 4, which illustrates fastener 20 in its full assembled position through a stepped aperture 50 preformed in a wooden railroad tie 44.

The aperture 50 is representative of the other four apertures associated with each tie plate and comprises a top uniform diameter portion 52, the diameter of which is just slightly greater than the diameter of the shank 28 of fastener member 22. The aperture 50 is enlarged at shoulder or step 54 to accommodate snug reception of the boss 36 of the fastener member 24. The aperture 50 is again enlarged eccentrically at shoulder 56 to provide a disc-shaped recess to accommodating anti-rotation reception of the base 42 of the fastener member 24. This relationship is illustrated in FIG. 5. Thus, when fastener 22 is rotated so that external threads 26 into or out of the internal threads 38, the eccentricity of the base 42 in respect to the boss 36 prevents fastener 24 from rotating.

When the tie 44 comprises two or more layers 51 without bonding agent at interface 49, the tightened two-part fasteners compressively hold the layers together and prevent misalignment of layers.

The bottom surface of the base 42, in FIG. 4, is illustrated as being sealed by a layer or coating of protective material 60, which prevents corrosion and deterioration of the base 42 by reason of the tie 44 resting upon ballast, which comprises part of a railroad track.

FIG. 4 also illustrates the placement of a railroad rail, as part of a two rail track, on tie plate surface 48, held there by conventional structure, not shown.

Reference is now made to FIG. 7 which illustrates a railroad tie 44′ formed of synthetic resinous or composite material. The aperture 50 shown in FIG. 7 is identical to aperture 50 shown in FIG. 4, with one exception. In lieu of the eccentric enlargement or recess 56, a concentric rectangular recess 56′ is provided. This accommodates anti-rotate reception of the rectangular or square base 42′ (FIGS. 2 and 6) in recess 56′, thereby preventing rotation of fastener member 24′ as the thread 26 of fastener member 22 are turned into or out of threads 38. While tie 44′ may be of dense material, the present invention may be utilized with tie materials which are softer than dense hard wood, composite and synthetic resinous materials.

Reference is now made to FIG. 8 which illustrates an additional two-part fastener embodiment in accordance with the principles of the present invention. The two-part fastener of FIG. 8 is generally designated 70 and comprises an upper or male fastener, generally designated 72, which comprises a head (not shown), which may be identical to head 30 of FIG. 1, and an extended shaft 28. The distal end 74 is threadless but comprises a diametrally enlarged male connector 76, for purposes yet to be explained.

Two-part fastener assembly 70 also comprises a lower or female fastener member 78, shown as being identical to fastener member 24, FIG. 1, except threads 38 have been eliminated and a female annular grove 80 added in lieu thereof. The boss portion 36 also is without an outside indentation. The male annulus 76 and female groove 80 are sized and shaped such that when the top fastener 72 is driven, with a sledge hammer or like instrument, the annulus 76 forcibly passes through the hollow of the boss 36 and come to rest in the groove 80. Thus, the two fasteners 72 and 78 become locked to prevent inadvertent separation notwithstanding the vibration caused by railroad trains moving along the railroad track.

Reference is now made to FIG. 9, which illustrates a further two-part fastener embodiment in accordance with the principles of the present invention, generally designated 90. Fastener assembly 90 comprises a top fastener member, generally designated 92, and a bottom fastener member, generally designated 94. Fastener member 92 comprises a head (not shown) similar to previously described head 30 and a shank or shaft 28 running the full length of the fastener 92 without external threads. At the lower blunt edge 96 it is found a threaded blind bore 98, the diameter of which is reduced at location 40 to create an anti-rotate binding site.

Fastener 94 comprises previously described eccentric base 42, shown as being formed as one piece or integrated with a threaded upright stud 99 such that the axis of the stud 99 is eccentric to the axis of the base 42 to prevent rotation of the fastener member 94 while in a tie aperture when the threads at 98 are turned into or out of the threads of bore 98. The engagement of detent 40 with the threads of stud 98 prevents inadvertent separation of fastener members 92 and 94 because fastener member 92 is constrained at 40 against rotation.

Reference is now made to FIG. 10, which illustrates, in diagrammatic form, one way in which pre-plated ties may be manufactured and stored in inventory or transported on vehicles for use. FIG. 10 is particularly significant in regard to the utilization of hard wood ties for which the present invention has particular application. In short, logs 100 are cut from trees 102 and thereafter, using commercial techniques, ties 44 are cut to size from logs 100. Ties 44 are pre-formed with a patterned array of apertures 50 located so as to become aligned with apertures into tie plates 46 placed on the top surface 45 of each tie 44.

A top fastener member of any of the types described above is placed, from the top, through each tie plate apertures 47 so as to extend into the associated tie aperture. A lower fastener member of the invention is placed from the bottom non-rotatably in the lower part of the associated tie aperture. The upper fastener member is connected against inadvertent separation to the lower fastener member, the connection being within the associated tie apertures 50, as explained above to create spikeless pre-plated ties, which may be stacked in inventory, as indicated at site 104, or placed on a vehicle and transported elsewhere for inventory or use purposes, as illustrated at site 106 in FIG. 10.

Different types of tie plates are used on various railroads. Tie plate 46, described above, consists of a tie plate which does not utilize spikes to hold a railroad rail in position. Other forms of tie plates do use spikes to hold railroad rails in position. One such tie plate, generally designated 120, is illustrated in FIGS. 11 and 12 to which reference is now made. Two tie plates are used with each tie 44, which may be one-piece or layered, only one of which is illustrated in FIGS. 11 and 12. Tie plate 120 comprises a base 122, the bottom surface 124 of which rests contiguously upon the top surface 45 of the tie 44. Base layer 122 is illustrated as having a width equal to the width of the tie 44. Base layer 122 is thicker at central portion 126, upon which a railroad rail 128 (FIG. 12) is placed so that the bottom surface 130 of the rail is contiguous with the central tie plate portion 126.

Each plate 120 also comprises an outside taper portion 132 and an inside taper portion 134. The tie plate 120 also comprises a pair of upright short flanges 136, which define the rail-receiving central portion 126. Each upright flange 136 is interrupted by two square vertically-directed apertures 138. A further square aperture 140 is centrally disposed in a vertical direction in each tapered end portion 132 and 134. Thus, each tie plate 120 comprises six apertures. The apertures 138 are adapted to each receive a railroad spike to retain rail 126 in position, as explained hereinafter in greater detail. Apertures 140 each receive two-part fasteners of the type explained above.

The tie 44 is pre-drilled at four locations, two for each tie plate 120, so as to create stepped vertically-directed apertures of the type described above at locations caused to be in alignment with apertures 140 when the tie plates 120 are correctly positioned on the top surface 45 of the tie 44. A two-part fastener 30 is caused to extend through each aperture 140 and each pre-drilled tie aperture 52 and thereafter tightened as shown and described in conjunction with FIGS. 4 and 7. FIG. 12 illustrates the two tightened two-part fasteners 30 by which the tie plate 120 is firmly and reliably joined to the tie 44. The rail 128 is initially positioned above and in contiguous relation with the central portion 126 of the tie 120 by force of gravity, followed by the driving of appropriately oriented spikes 142 through each aperture 138 and into the material comprising the tie 44 so as to securely and reliably hold the rail in its operable position. See FIG. 12.

Layered ties used with two-part fasteners of the present invention have significant advantages. They are environmentally friendly because use of discarded pre-used ties as a raw material does not mandate harvesting of new ties from living trees. Furthermore, this approach is cost-effective because the discarded ties are paid for. The layers, for multi-layer ties to be used with two-part fasteners of this invention, are simply conventionally cut from the discarded ties and the resulting layers are stacked, bonded, if desired, drilled and caused to receive two-part fasteners in the manner described above.

The invention may be embodied in other specific forms without departing from the spirit of the essential characteristics thereof. The present embodiments, therefore, are to be considered in all respects as illustrative and are not restrictive, the scope of the invention being indicated by the appended claims rather than by the foregoing description, and all changes which come within the meaning and range of equivalency of the claims are therefore intended to be embraced therein. 

1. A pre-plated railroad tie assembly comprising: a railroad tie comprising a top surface and a bottom surface, the tie having at least two apertures extending between the top and bottom surfaces of the tie; two spaced tie plates contiguous with the top surface of the tie, each tie plate comprising several apertures at least one of which is aligned and size compatible with each tie aperture; a two part fastener disposed in each pair of aligned tie and tie plates apertures, one fastener comprising connected first and second members; each first fastener member comprising a head disposed above and tightly contiguous with the tie plate and a depending shaft extending through the one tie plate aperture and into the aligned tie aperture; each second fastener member comprising a boss disposed in the associated tie aperture and an anti-rotate base disposed below the boss; at least one spike driven into the tie through another of the apertures in each tie plate.
 2. A pre-plated tie assembly according to claim 1 wherein the connection between the first and second fastener members comprises an anti-rotate threaded connection which alleviates inadvertent loosening of the fastener members.
 3. A pre-plated tie assembly according to claim 1 wherein number of two part fastener in each tie plate is selected from the group consisting of one and two and the number of spikes driven through tie plate apertures is selected from the group consisting of four and five.
 4. A pre-plated tie assembly according to claim 1 wherein the railroad tie comprises a plurality of layers.
 5. A method of pre-plating a railroad tie comprising the acts of: providing a railroad tie comprising a top surface and a bottom surface; creating at least two apertures arranged in the tie between the top and bottom surfaces; placing two tie plates, each having a pattern of apertures, on the top surface of the tie so that at least one tie plate aperture of each tie plate is aligned with at least one aperture in the tie; lowering a shaft fastener, comprising a proximal head and a distal end, through each of the at least one tie plate aperture in each tie plate and into the associated aligned tie aperture; placing an anti-rotate fastener in a lower portion of each tie aperture; connecting the two fasteners in each tie aperture together until the head is tight against the associated tie plate; driving at least one spike into the tie through at least one aperture in each tie plate.
 6. A method according to claim 5 wherein the providing act comprises providing a railroad tie comprised of at least two layers.
 7. An assembly comprising an apertured tie plate secured contiguous with a top surface of an apertured railroad tie the assembly further comprising: at least one shaft fastener member placed in aligned tie plate and tie apertures and comprising an enlarged proximal head tightened against the tie plate, a central shaft and a distal end; an anti-rotate fastener member placed in the tie aperture and comprising a boss whereby the shaft fastener member is connected in tight relation with the anti-rotate fastener member; at least one spike driven into the tie through another tie plate aperture.
 8. An assembly according to claim 7 wherein the railroad tie comprises at least two layers.
 9. A railroad comprising two spaced railroad rails: a plurality of spaced apertured railroad ties supporting the rails; each tie comprising a top surface, a bottom surface and at least two stepped apertures spanning between the top and bottom surfaces of the tie; two spaced apertured tie plates contiguous with the top surface upon which the respective railroad rails are supported, at least one tie plate aperture being aligned with the as tie aperture; a two-part fastener disposed in at least two pairs of aligned tie and tie plate apertures; one fastener part comprising a fastener element comprising a proximal tie plate engaging head and distal threads; the other fastener part comprising a fastener element comprising threads threadedly connected to the distal threads and an anti-rotate element; at least one spike driven into the tie through at least one aperture in each tie plate.
 10. A railroad according to claim 9 wherein at least one of the railroad ties comprises a multi-layer tie.
 11. A pre-plated railroad tie assembly comprising: a railroad tie comprising a top surface and a bottom surface, the tie having at least two apertures, each tie aperture extending between the top and bottom surfaces of the tie; two spaced tie plates contiguous with the top surface of the tie, each tie plate defining apertures at least one of which is aligned and size compatible with the one tie aperture; a two-part fastener disposed in each tie plate aperture; each first part fastener comprising a proximal head disposed above and contiguous with the tie plate and a depending shaft passing through an associated tie plate aperture and a first connector element at a distal end portion of the shaft; each second part fastener comprising a second connector element and an anti-rotate base disposed below the second connector element within the tie aperture; at least one spike driven into the tie through at least one aperture in each tie plate.
 12. A pre-plated railroad tie according to claim 11 wherein the railroad tie comprises at least two vertically stacked layers. 